Apparatus for underglaze ceramic decoration



United States Patent [72] Inventor .1 Valid 2,842,046 7/1958 Murray 101/41 31 23 31ml, N York, New York 2,851,944 9/1958 Prohaska... 101/44 10011 2,917,994 12/1959 Tripp ll/379X [21] AppL'No. 682,374 3,146,703 9/1964 Mason et a1. 101/125 [22] Filed Nov. 13,1967 3,277,819 /1966 Berkland l0l/l25 Patented Sept. 29, 1970 FOREIGN PATENTS 5,612 6/1927 Australia 101/41 APPARATUS FOR UNDERGLAZE CERAMIC Primary Examiner-Robert E. Pulfrey DEC ATl Assistant Examiner-Clifford D. Crowder 4 Claims, 17 Drawing Figs. A ttorne y Polachek and Saulsbury [52] U.S.CI 101/41, 101/115, l0l/l25, 101/126, 101/201, 101/379, l0l/407,9l/35,269/l56,269/225 [I11- Apparatus for appIying underghze d orati B41H5/04, 27/26 patterns to porous surfaces of ceramic articles made of baked Field ofSearch 101/ 125, lay. A printing plate assembly having a matrix made of 1 15, 126,201, 379, 35,41 44, 407; 91/ 35(C r 0 'y); resilient foam plastic pad, coated or covered on one side with 269/ 15610115011), 225(Cursory) a nonporous film. The film has open areas defining decorative patterns on exposedportions of the foam pad. The pad is [56] chum Cited backed by a perforated plate with a surrounding wall arranged UNITED STATES PATENTS to contain ink which flows by gravity through the pad to the 659,535 1011900 Lankford 101/115UX article being decorated. The apparatus includes a centering 834,181 10/1906 Bell 101/41 device for aligning the printing plate assembly with the article 1,929,703 10/1933 McDonough.. 101/43 being decorated. The apparatus can be operated manually or 2,372,089 3/1945 Keller et al. 101/41 semiautomatically. An air pressure driven piston carries the 2,493,953 1/1950 Emerson 101/41 printing plate assembly with associated timer, limit switches, 2,603,149 7/1952 Mann 101/41 and val Matrices of various shapes y be used- 4 l 32 l 36 30 76 3 i 29 a w h so 4 4 5' I #6 n w I w 50 l 4 25/ Q o 9 19 1 28 3 5| 77 E i a i m I l 38 c4 3; 134 l H q 7 l\\ a I a I1 I 1 m 20 12 25 136 1 116 Patented Sept. 29, 1970 Sheet 8 UPPL Y 70 POWER INVENTbR l/a/ie /a BY 9L Vim/wa 5 Jose Patented. Sept. 29, 1970 3,530,792

INVENTOR Jos Volie/a Arm 3 TEE 8 n 6 a m w 117 f fim rl\ fl o 1 ,1 6 mm (la u 3 8 .n 2 w. I E a 1 I m R m--.. 6 S 1 mafimrrflnn H w mm 1 9 in w 1 mmsm 1 aw a 5 a "M 2 2 H M a m wmm a M 1 0 .m m 4 2 a w m 1 e 5 n p INVENT OR Vol/e l0 Jose Patented Sept. 29, 1970 4 v of 6 Sheet INVENTOR l o/l'e la Jos . ATTDRN Patented Sept. 29, 1970' t 3,530,792

Slgeet 6 re INVENTOR 1031; r I g l/os Val/'e/a I 41mm:

APPARATUS FOR UNDERGLAZE CERAMIC DECORATION This invention relates to underglaze ceramic decoration and more particularly concerns a process and apparatus for printing on bisque. Bisque is a term applied to ceramic articles such as plates, cups, tiles and the like, previously molded from clay, as they come out of firing kiln after the first fire.

In general, there are two important types of decoration applied to ceramic underglaze and overglaze. The first is made on the porous and absorbent parts of bisques; the second is made after a second firing which is performed in a glazing kiln. Since the second or overglaze type of decoration is made on a glazed surface, a third firing is required to fix the decoration. In general the underglaze type of decoration is preferred because it is more economical, i.e. two firings rather than three are required. Furthermore, since the underglaze decoration is covered and protected by glaze this decoration is more durable than the overglaze type of decoration. The present invention requires a porous absorbent printing surface, so it is best adapted for printing directly on bisques in making underglaze decorations.

According to the invention, a resilient sheet or pad of high density plastic foam made of a synthetic material such as polyethylene, polyester, polyether, polyurethane, etc. is used in making a printing plate. The pad is covered on one side with a nonporous film having open areas where the porous surface of the pad is exposed. The nonporous film can be reinforced with a flexible lacquer or resin leaving exposed the open areas of the pad representing the decorative pattern. The pad is attached at its other side to a perforated metal sheet plate or screen shaped or arranged to serve as a container for printing ink. This perforated plate is rigid and serves as a support in applying pressure to the matrix which consists of the resilient foam pad and film coating, or a bonded silk screen, photographically obtained.

The apparatus for applying the decoration to a bisque article can be semiautomatic or nonautomatic in operation. One form of the apparatus includes an air cylinder in which is a slidable piston carrying a printing plate assembly. The apparatus includes a platform on which the bisque article is mounted. The platform is part of a centering device for axially aligning the bisque article with the printing plate. The printing plate is applied to the flat or curved surface of the bisque article and colored ink fiows through the matrix to the surface of the bisque article being decorated. When the printing plate is withdrawn, the bisque article remains on the platform with the desired decoration imprinted thereon. The article can then be taken off and replaced by another one. In another type of apparatus, the bisque article is rotated while in contact with the resilient side of the matrix of a printing plate. The ink flowing through the porous pad and open exposed areas is deposited on the rotating bisque article to form the desired decorative pattern thereon.

The matrix of the printing plate can be prepared photographically. In this method the pad is initially coated on one side with a light sensitive emulsion. This coated side is exposed to light through a transparent positive film carrying the decorative image. The image is opaque while other parts of the film are clear. After exposure to light the parts of the emulsion which were exposed to the light become hardened. The other parts of the emulsion representing the decorative pattern remain soluble. These soluble parts wash off in subsequent development of the film in a warm water bath. This leaves uncoated porous surface areas on the pad through which ink can pass. All other parts of the pad are coated with a nonporous adherent, insoluble film. 1

It is possible to prepare the matrix consisting of a resilient foam pad and film coating by applying fast drying lacquer to the pad entirely by hand. Open, uncoated areas, define the decorative pattern. It is also possible to prepare the matrix by cementing a nonporous, flexible fabric nylon sheet to the resilient pad. The nylon sheet will have cutouts or openings representing the decorative pattern. Alternatively the nonporous film on the foam pad can be thermoplastic or thermosetting resin applied by a printing plate or roller, or a metal screen plate. v

The thickness of the foarn pad employed in making a matrix depends on the structure of the bisque article involved. A flat tile can be decorated by using a thinner matrix than a bowl, dish or cup. In general the thickness of the pads will range from one-sixteenth of an inch to three-eighths of an inch. The amount of ink applied to the bisque article is determined by the pressure applied to the matrix and the time and pressure is applied, and does not depend on the thickness of the matrix pad. The amount of ink applied also depends on the viscosity and composition of the ink. Many types of ink can be used. They can be composed of pigments in water which is quickly absorbed by the bisque. An ink containing arabic gum retards absorption so the decorative pattern remains on the surface of the bisque. Also light oil base inks are absorbed more than those with heavy oil base. The inside part of the plate forms a container for the ink.

The back of the printing plate can be arranged with compartments for containing different colored inks, so that differently colored patterns will be applied in different areas of the decorated bisque article. The printing plate may be fabricated with a flat, concave, convex, frustoconical or other shaped matrix depending on the shape of the surface to which the printing plate will be applied.

It is therefore a principal object of the invention to provide a novel process and apparatus for applying an underglaze decoration to a bisque article.

Another object is to provide a new method and apparatus in which a decoration can be applied rapidly, in one or several colors, on flat, curved or irregularly shaped bisque articles.

A further object is to provide a method and apparatus for applying an underglaze decoration to a bisque article in which is avoided the use of inking rollers, silk screens Squeegees, and other conventional methods and devices heretofore used for the purpose.

Another object is to provide a method and apparatus described in which ink flows by gravity through a matrix to a ceramic surface being decorated.

Another object is to provide an apparatus which prints the decorative pattern on an article of bisque in one stroke regardless of the shape of the article.

A further object is to provide a process and apparatus for printing on ceramic surfaces, in which decorations are applied accurately and uniformly, piece after piece in rapid sequence.

Still another object is to provide a method and apparatus as described, which can be used in commercial potteries by relatively unskilled labor, at low cost, with great economies effected in expenditure of time, effort and materials.

For further comprehension of the invention and of the ob ject and advantages thereof, reference will be had to the following description and accompanying drawing and to the appended claims in which the various novel features of the invention are more particularly set forth.

In the accompanying drawing forming a material part of this disclosure:

FIG. 1 is a side view of an apparatus embodying the invention.

FIG. 1A is a perspective view of a printing plate holder used in the apparatus.

FIG. 2 is an enlarged side view, partially in section, of a switch actuator employed in the apparatus of FIG. 1.

FIG. 3 is an enlarged top plan view taken on the line 3-3 of FIG. I and showing a centering device for aligning a bisque article to be decorated with a printing plate assembly in the apparatus.

FIG. 4 is a sectional view taken on line 4-4 of FIG. 3.

FIG. 5 is a cross-sectional view taken on line 5-5 of FIG. 4.

FIG. 6 is a side view of another apparatus embodying the invention.

FIG. 7 is a plan view with portions broken away of a printing plate, according to the invention.

FIG. 8 is an enlarged cross-sectional view taken on line 8-8 of FIG. 7.

FIG. 9 is an enlarged vertical sectional of a printing plate assembly such as employed in the apparatus of FIGS. 1 and'6, shown in position for applying a decoration to a bowl mounted on a platform of a centering device in the apparatus.

FIG. 10 is a top plan view of the printing plate assembly, taken on line 10-10 of FIG. 9.

FIG. 11 is a top plan view of another printing plate assembly for applying multicolor decorations.

FIG. 12 is a cross-sectional view taken on line 12-12 of FIG. 1 1.

FIG. 13 is an oblique view of a flat tile bisque having multicolor decorations applied by use of the assembly of FIGS. 11 and 12.

FIG. 14 is a side view partially in section of another printing plate assembly employed for decorating the interior of a deep dish or bowl.

FIG. 15 is a side view partially in section of apparatus for applying an underglaze decoration to the outside of a cylindrical cup.

FIG. 16 is a side view partially in section of a printing plate assembly for applying a decoration to a convex surface of a bowl.

Referring first to FIG. 1, there is shown a machine 20 which includes a table 22. The table has a horizontal top 24 in which is a hole 25. Mounted on the table top 24 by bolts 26 is an inverted U-shaped frame 28. On the top 29 of the frame is a cupshaped support 30 for hydraulic cylinder 32. The support 30 has an annular flange 34 secured by bolts 36 to the top 29 of the frame 28. A cylindrical head 38 is disposed on top of the cylinder and is secured by rods 39 and nuts 40 to support 30. In the cylinder is a movable piston head 42. From head 42 a piston rod 44 extends downwardly through registering holes in the support 30 and frame top 29. The lower end of rod 44 is secured by bolts 45 in a hub 46 which is integral with spider arms 48. These arms at integral with a horizontal ring 50 provided with holes 52 to receive bolts 54; see FIG. 1A.

Detachably secured to ring 50 by bolts 54 is flanged ring 56 of a printing plate assembly 60. This particular assembly has a depending convex matrix 62 arranged to contact the inner concave side of side of a bowl B shown disposed on platform 64 of a centering device 65.

The cylinder 32 is filled with fluid supplied from a remote source via a conduit 66. A filter, flow regulator and lubricator 68 is interposed in the conduit. The conduit 66 is connected to an inlet of a solenoid-operated valve 70. The valve has two conduits 72 and 74 connected to flow control valves 75, 76 respectively located at upper and lower ends of the cylinder 32. By means of valve 70, the flow of fluid into the cylinder is regulated so that when conduit 72 feeds fluid to the cylinder to lower the piston and printing plate assembly, conduit 74 conducts fluid away from the cylinder; and when conduit 74 feeds fluid to the cylinder to elevate the piston and printing plate assembly, the fluid flows out of conduit 72.

Connected in circuit with the valve by wires 77, 78 is a timing device 79 and two limit switches 80 and 82. Switch 80 is supported just under frame top 29. Switch 82 is secured on a support 83 attached to one side of frame 28. Spider arms 48 carry switch tripper 85 best shown in FIG. 2. The switch tripper has an axially vertical cylindrical body 86 in which is a vertically slidable rod 88 having flanges 89, 90 at opposite ends. Coil springs 91, 92 are mounted on the rod between the flanges and tripper body 86. On body 86 is a laterally extending bolt 94 which engages in a threaded hole 95 in one of the spider arms. The switch tripper is disposed to close either switch button 80 or 82 at opposite ends of travel of the printing plate assembly 60. The structure of the printing plate assembly 60 is best shown in FIGS. 9 and 10. The assembly includes a channel-shaped flanged ring 56. The upper horizontal annular flange 98 has threaded holes 99 which receive bolts 54 so that the assembly is attachable to and removable from ring 50. The lower flange 100 is welded to annular flange 102 formed at the periphery of a bowl-shaped perforated plate 104. This plate has numerous holes 105 distributed throughout. This plate cah serve as a container for ink 106 and carries matrix 62. Bonded to the convex underside of plate 104 is a pad 108 made of porous resilient foam. This pad can be made of polyethylene, polyester, polyurethane, neoprene, or even natural rubber, depending on the composition of the ink. Some materials are more resistant than others to decomposition in the presence of certain liquid ink media such as oil, water, alcohol, etc. Bonded to the convex underside of pad 108 is a thin, nonporous film or layer 110. In film 110 are openings 112 defining a decorative pattern to be impressed on the inner concave side 114 of bowl B.

The bowl rests on platform 64 of a centering device 65 best shown in FIGS. 3, 4 and 5 to which reference is now made. The platform 64 includes a flat circular plate 116 on which is secured a resilient mat 1 18 of rubber or other suitable material. Secured to the underside of plate 116 are three anchors 119 for three equally spaced bolts 120. The bolts extend vertically and are engaged in threaded holes 122 of a base plate 124. The base plate is mounted by bolts 123 on table top 24 over hole 25. The bolts extend through hole 25 and can be turned for adjustably elevating and lowering the platform 64, depending on the thickness and height of the bowl or other ceramic article to be underglaze decorated while on platform 64.

The centering device further includes a centrally located spur gear 126 rotatably held by a central stub shaft 128 to base plate 124. Extending radially from hub 130 of the gear is a handle bar 132 terminating in a ball handle 134. A coil spring 136 is engaged between the handle and plate 124 to keep the handle and plate 124 in the angular position shown best in FIG. 5. Three other spur gears 138 are rotatably mounted by a stub shaft 140 to plate 124. These gears are centered 120 apart circumferentially of gear 126. The hub 142 of each gear carries an L-shaped radially-extending arm 144. Mounted vertically at the outer end of each arm 144 is a rod 146. Each rod has a resilient rubber or plastic jacket or sleeve 148. The three rods serve as guides and as pushers for centering bowl B on the platform. Normally the rods are spaced radially away from the rim of the bowl. When the handle 134 is moved angularly as indicated by dotted lines in FIG. 5, the arms 144 will turn inwardly of the base plate. Since the centers of rods 146 always define apices of an equilateral triangle in all positions, they will contact the periphery of the bowl and move it to center it precisely in axial alignment and registration with the axis of the printing plate assembly 60. When the handle 134 is released, the spring 136 moves the handle back to the solid line position of FIG. 5 and the arms 144 with rods 146 move outwardly away from the bowl to clear the path for descent of the printing plate assembly.

The apparatus 20 arranged as shown in FIG. 1 can operate automatically after the bowl is manually centered on the centering device 65. In operation, the bowl is put on platform 64 and is manually centered while the printing plate assembly 60 is elevated. The timer 79 is set to provide two delay times of about 1 second each. After one delay time the printing plate assembly is lowered on the centered bowl and ink which has flowed gravitationally through pad 108 is applied to the surface 114 of the bowl via openings 112 in film 110. During the next delay time the printing plate assembly dwells for about 1 second in contact with the bowl. Then the printing plate assembly is raised to permit the decorated bowl to be removed and another bowl is placed on the platform. The speed of up and down movement of the piston and printing plate assembly is controlled by the setting of the flow control valves 75 and 76. Each time the switch tripper 85 reaches the upper and lower end of its travel it actuates switch 80 or 82 to activate valve 70 and for reversing the flow of fluid through conduits 72, 74. The cylinder is double acting since it raises and lowers the piston under fluid flow control.

In FIG. 6 is shown another apparatus 20A which is generally similar to apparatus 20 and corresponding parts are identically numbered. In apparatus 20A the operation is semiautomatic. There is provided a foot operated valve 150 which applies fluid pressure to a check valve 151 to valve 152. Only one conduit 72' is connected to valve 152 to apply fluid pressure to the top of piston head 42' in cylinder 32. Cylinder support 30a is closed at the side. Coil springs 165 are connected between the top 29a of frame 28a and spider arms 48a. Valve 152 is a timed valve which operates so as to hold the printing plate assembly 60 in contact with inner side 114 of bowl B for a predetermined time to effect application of the ink pattern to the bowl. Each time valve 150 is pressed and released, one cycle of operation occurs and one application of the lowering and raising of the printing plate assembly occurs.

Instead of a bowl, a flat bisque article such as a tile can be decorated. FIGS. 7, 8, 11 and 12 show the flat configuration of a matrix 62a used for applying a decorative pattern to a flat tile. The pattern is defined by holes 112a in nonporous film or layer 110a applied to the underside of flat pad 108a. The rigid backing plate 104a is flat. The holes 105a can be staggered in successive rows or can be aligned with each other. In order to contain printing ink the plate 104a can have an upstanding peripheral wall 170 best shown in FIGS. 11 and 12. Wall 170 is formed with a laterally extending flange 172 which can be attached to ring 50 in apparatus 20 or 20A. Ring 50 can be rectangular in shape like flange 172 for fitting the flange more closely to the ring.

If differently colored patterns are desired, then partitions 176 can be secured by welding inside the wall 170 on a plate 104:: as shown in FIGS. 11 and 12. Five differently colored inks 106a are contained in the several compartments defined by crossed partitions 176. Thus differently colored decorations 181 are applied to bisque tile T shown in FIG. 13. Application of the differently colored decorations is accomplished in one stroke of the printing plate assembly 60a of FIGS. 11 and 12, when apparatus or machine 20 or 20A is used. More or less than five compartments can be provided. The partitions need not be straight. They can be curved as shown by partition 176' and can even have walled off compartments as indicated by circular partitions 176". Other partition configurations are possible.

If the inner surface of a dish is to be decorated, the printing plate assembly 62b of FIG. 14 may be used. Here the perforated metal back of the assembly l04b has a perforated frustoconical side 190 and circular bottom 191. A correspondingly shaped frustoconical matrix 62b is attached to the outside of the wall 190. A round, flat matrix 62a is attached to the flat bottom 191 of wall Printing ink 106b is contained in the dished back of the assembly and passes through holes 105b, porous pads 108b, 108b', and holes 112b in the pads to the inner surfaces of the bisque disk dish to be underglaze decorated.

If the convex outer surface of a bowl is to be decorated, the printing plate assembly 60c of FIG. 16 can be used. Here the inner back wall 1046' is dome shaped and resilient, porous pad 1080 is bonded to the bottom concave side of wall 1040. The concave side of the pad is coated with nonporous film 1100 having holes 112c defining the pattern to be printed on the convex side ofa bowl. An upstanding cylindrical wall 194 surrounds wall 1040 and its bottom flange 195 is welded to annular flange 196 of wall 104a. Ink 1060 is thus contained in-the container defined by the cylindrical wall 194. Wall 194 has annular flange 197 to which ring 50 can be attached for mounting the assembly 60c in apparatus 20 or 20A.

FIG. shows how printing plate assembly 6012 of FIGS. 11 and 12 can be used in another type of apparatus 208. In this apparatus, the peripheral flange 172 is attached to the underside of a horizontal carrier plate 200 carried by a pair of horizontal parallel rods 202. A cylindrical cup or mug M is rotatably supported on a horizontal axis by turning shaft 204 which has a head 206 abutting the bottom 205 of the mug. Another rotating head 208 abuts the inner side of the mug. As the mug rotates counterclockwise as indicated in FIG. 15 the carrier 200 and printing plate assembly 60b move to the left.

Thus the mug is decorated with patterns applied by ink passing through the matrix 62a to the bisque mug.

In all forms and methods embodying the invention described, there is employed a matrix having a rigid perforated back arranged to define a container for ink which passes gravitationally and by capillarity through the porous pad of the maxtrix. In all forms and methods of the invention, the matrix is applied for a predetermined time to insure proper applications of the printing ink to the surface of the bisque being decorated. Application is effected automatically, with manual operations reduced to the minimum.

While I have illustrated and described the preferred embodiments of my invention it is to be understood that I do not limit myself to the precise construction herein disclosed and that various changes and modifications may be made within the scope of the invention as defined in the appended claims.

lclaim:

1. Apparatus for applying a decorative underglaze pattern to a surface of an article of a bisque comprising a printing plate assembly having a rigid perforated backing plate shaped to contain printing ink, a resilient porous pad secured at one side to the backing plate for receiving said ink through holes in the backing plate, a nonporous layer applied to the other side of the pad and having openings therein defining said decorative pattern, said pad being exposed at said openings for passing said ink to the article when the printing plate assembly is pressed against said article, said backing plate having means for mounting said printing plate assembly to a movable support for applying the printing plate assembly against said article, a vertically-extending fluid pressure cylinder device having a vertically-movable piston operatively connected to said printing plate assembly to apply the same against said article when the piston is extended, a platform disposed underneath said printing plate assembly for supporting said article while the assembly is applied to the article, a centering device for the article on the platform having a horizontal base plate adjustably carried on said platform, said centering device having a first rotatable gear centrally-disposed on said base plate, three other gears disposed on said base plate and meshed with said first gear, said other gears being rotatable on axes spaced circumferentially apart, arms connected to said gears and extending radially outward thereof, upstanding rods carried at outer ends of the arms and circumferentially-spaced around said platform, a handle secured to the first gear and extending radially thereof to rotate the first gear and move the rods inwardly to contact and to center the article with respect to the printing plate assembly, adjustable bolts on said horizontal base plate and engaged with said platform for adjustably elevating and lowering the platform depending on the size of article to be printed and an adjustable timer controlled valve means operatively connected to and controlling the flow of fluid in said cylinder so that the printing assembly is held against the article for a predetermined but adjustable time after the printing plate assembly is advanced downwardly toward the platform.

2. Apparatus as recited in claim 1 wherein the bisque article has a flat surface, and wherein said backing plate and matrix are flat to conform with the flat surface of the bisque article for marking the same, and wherein said assembly has a cylindrical wall surrounding the backing plate and defining a container for said ink.

3. Apparatus as recited in claim 2, wherein said printing plate assembly has at least one partition secured to said cylindrical wall over said backing plate and defining a plurality of compartments for containing printing ink of different colors in the respective compartments.

4. Apparatus as recited in claim 1, wherein said bisque article is dished shape with a flat bottom and conical side and wherein said backing plate has a flat bottom perforated portion and perforated conical side wall portion to conform with said bottom and side of said bisque article, said pad being secured to the bottom of the backing plate, and a matrix attached to the conical side wall portion of the backing plate for applying a decorative pattern to the conical side of said dished shaped article, said matrix having another resilient porous pad for receiving ink through holes in the conical side wall portion, and another nonporous layer covering said other resilient 

